Hydrophilic Medical Device Substrate Integration
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Solution Overview
Problem
Existing hydrophilic medical devices face issues with costly and environmentally unsatisfactory coating processes, inadequate water retention, poor adherence to substrates, high friction when wetted, and mechanical property deficiencies, particularly in urinary catheters which require long-term shelf stability.
Innovation Solution
A medical device with a hydrophilic surface layer formed as an integral part of a polymer blend substrate, comprising a higher concentration of hydrophilic polymer, which is cross-linked to create a robust, low-friction surface that is stable and cost-efficient to produce, using a method involving a polymer blend of base and hydrophilic polymers, and optionally additional support layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hydrophilic coating is applied to the substrate, then low-friction surface character is achieved, but manufacturing cost increases and environmental harm occurs
Solution Approach 1:
The invention merges the substrate and hydrophilic coating into a single integrated component. The hydrophilic polymer is incorporated directly into the substrate material matrix, eliminating the need for separate coating application processes. This integration reduces manufacturing steps, lowers costs, and eliminates environmental concerns associated with coating solvents and processes.
Solution Approach 2:
The invention uses composite materials by combining the substrate material with hydrophilic polymer within the substrate structure. This creates a multi-phase material where the hydrophilic polymer forms dispersed phases or networks within the substrate, providing low-friction properties without requiring a separate coating layer.
2Ease of operation
If a hydrophilic coating is applied to the substrate, then low-friction surface character is achieved, but adherence to substrate deteriorates over time
Solution Approach 1:
By merging the hydrophilic polymer with the substrate material matrix, the invention eliminates the interface between coating and substrate that causes adherence problems. The hydrophilic polymer becomes an integral part of the substrate structure, ensuring permanent attachment and preventing delamination or degradation of the low-friction surface over time.
3Ease of operation
If a hydrophilic coating is applied to the substrate, then low-friction surface character is achieved, but water retention properties are insufficient after leaching
Solution Approach 1:
The composite material structure with hydrophilic polymer distributed within the substrate matrix provides superior water retention. The hydrophilic polymer phases act as water reservoirs that continuously supply moisture to the surface, maintaining low-friction properties even after prolonged use and leaching, unlike surface coatings that lose their hydrophilic properties when the coating layer depletes.
4Ease of operation
If conventional coating processes are used, then hydrophilic surface is achieved, but the process is cumbersome and costly
Solution Approach 1:
The invention combines substrate manufacturing and hydrophilic surface creation into a single process step. By incorporating the hydrophilic polymer during substrate fabrication, the need for separate coating processes is eliminated, significantly simplifying manufacturing and reducing costs.
5Reliability
If the substrate is made entirely of hydrophilic polymer, then excellent water retention is achieved, but mechanical properties become inadequate
Solution Approach 1:
The composite material structure combines the mechanical strength of the substrate material with the water retention properties of the hydrophilic polymer. The substrate material forms the continuous matrix providing structural integrity, while the hydrophilic polymer dispersed within it provides water retention and low-friction properties, achieving both requirements simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides excellent water retention, stability, and low-friction properties, maintaining performance over time without the need for conventional coatings, and is suitable for long-term storage and use in medical devices like urinary catheters.
Implementation Method 1
arranging the substrate in a wetting liquid, whereby the at least one hydrophilic polymer migrate(s) towards a surface of the substrate
Implementation Method 2
irradiating the substrate, thereby forming cross-linking between the polymers
Implementation Method 3
a hydrophilic surface layer providing low-friction surface character of the medical device when wetted by a wetting fluid
Data Source
AI summary
A medical device, such as a catheter, is disclosed, comprising a substrate and having on its surface, on at least a part thereof, a hydrophilic surface layer providing low-friction surface character of the medical device when wetted by a wetting fluid. At least one base layer of the substrate, including the hydrophilic surface layer, is made of a polymer blend comprising at least one base polymer and at least one hydrophilic polymer, and wherein the concentration of the at least one hydrophilic polymer is higher in the hydrophilic surface layer than in the rest of the base layer. A method for producing such a medical device is also disclosed.